WO2014129640A1 - 圧着端子の製造方法、圧着端子及びワイヤハーネス - Google Patents
圧着端子の製造方法、圧着端子及びワイヤハーネス Download PDFInfo
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- WO2014129640A1 WO2014129640A1 PCT/JP2014/054393 JP2014054393W WO2014129640A1 WO 2014129640 A1 WO2014129640 A1 WO 2014129640A1 JP 2014054393 W JP2014054393 W JP 2014054393W WO 2014129640 A1 WO2014129640 A1 WO 2014129640A1
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- crimp terminal
- laser
- crimp
- crimping
- welding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/21—Bonding by welding
- B23K26/24—Seam welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
- B23K26/03—Observing, e.g. monitoring, the workpiece
- B23K26/0344—Observing the speed of the workpiece
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0221—Laser welding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R2201/00—Connectors or connections adapted for particular applications
- H01R2201/26—Connectors or connections adapted for particular applications for vehicles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
- H01R4/203—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact
- H01R4/206—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/005—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
- Y10T29/4921—Contact or terminal manufacturing by assembling plural parts with bonding
- Y10T29/49211—Contact or terminal manufacturing by assembling plural parts with bonding of fused material
- Y10T29/49213—Metal
- Y10T29/49215—Metal by impregnating a porous mass
Definitions
- the present invention relates to a method of manufacturing a crimp terminal responsible for connection of an automobile wire harness, a crimp terminal, and a wire harness.
- Wire harnesses are frequently used for in-car wiring of automobiles.
- the wire harness is a set of a plurality of covered electric wires in a collective part according to the specifications of in-vehicle wiring.
- a crimp terminal is crimped to the end of each covered electric wire.
- connection part of a crimp terminal and an electric wire terminal is resin-sealed in order to prevent the corrosion of a core wire by the penetration
- the wire connection part (crimp part) of the crimp terminal is bent into a cylindrical shape by press molding, and the entire butt interface at both ends of the plate material formed into the cylindrically bent portion is joined by laser welding. Attempts have been made to make the electric wire connection part a sealed structure by joining one end of the bent part into a shape by laser welding and sealing to form a barrel member as a sealing part.
- the joint strength of the welded part by laser welding mainly depends on the intensity of the laser beam irradiated on the welded part and the sweep speed.
- the bonding strength of the welded portion of the crimping portion becomes insufficient.
- crimps a crimp terminal to an electric wire terminal, it becomes a cause which a crack generate
- the crimping shape of the core wire portion and the crimping shape of the coating portion are greatly different. This is because the core wire part must have an optimal crimping shape to stabilize electrical continuity, and the coating part must have an optimal shape to prevent moisture from entering the cylindrical barrel through the gap between the terminal and the wire coating. It is. For this reason, there is a possibility that a complicated force acts on the terminal when the electric wire and the terminal are crimped, and the welded portion is cracked.
- weld bead the weld mark
- the problem to be solved by the present invention is to manufacture a crimp terminal capable of laser welding a workpiece with high quality by controlling the intensity and sweep speed of the laser beam applied to the welded portion to appropriate values.
- the present invention provides a method and a crimp terminal, and further provides a wire harness provided with the crimp terminal.
- a method of manufacturing a crimp terminal is a method of manufacturing a crimp terminal including a crimp part that allows crimp connection to a conductor portion of a covered electric wire, and the sides of a metal plate material Are joined to each other to form a cylindrical body, and laser light is irradiated from the laser irradiation means around the combined sides to weld the combined sides and welds formed on the sides after welding
- the power density of the laser light and the sweep speed of the laser light are set so that the width of the bead is 80 ⁇ m to 390 ⁇ m.
- the laser light source of the laser irradiation means is preferably a fiber laser.
- the width of the weld bead is preferably 101 ⁇ m to 365 ⁇ m, more preferably 172 ⁇ m to 273 ⁇ m.
- the power density of the laser beam and the sweep rate of the laser beam so that the width dimension of the weld bead formed on the side portion after welding is 180 ⁇ m to 270 ⁇ m.
- the thickness of the cylinder to be irradiated with laser light to 0.8 mm or less.
- the crimp terminal which concerns on this invention is a crimp terminal provided with the crimping
- plate material were mutually match
- the laser light source of the laser irradiation means is preferably a fiber laser.
- the width of the weld bead is preferably 101 ⁇ m to 365 ⁇ m, more preferably 172 ⁇ m to 273 ⁇ m.
- the thickness of the mating part is preferably 0.8 mm or less.
- the mating portion is formed by abutting the side edges or overlapping the side edges.
- the wire harness of this invention is a wire harness which has a 1 or several covered electric wire, Comprising: The crimp terminal of any one of Claims 6 thru
- the conductor portion of the covered electric wire is made of aluminum or an aluminum alloy.
- the workpiece can be laser welded with high quality, and a crimp terminal having a high quality crimp portion can be manufactured.
- a simple method of setting the weld bead width and measuring the weld bead width after laser welding it is possible to guarantee a crimp terminal that maintains reliability even after crimping.
- FIG. 1 It is a perspective view which shows the state which connects a wire cable to a crimp terminal. It is a top view of a crimp terminal. It is a perspective view which shows the example of another crimp terminal. It is a schematic diagram which shows the structure of a terminal manufacturing apparatus.
- A) is a top view which shows a copper strip
- (b) is a top view which shows the chain terminal after a primary press
- (c) is a top view which shows the chain terminal after a secondary press.
- FIG. 1 is a perspective view illustrating a state in which a wire cable is connected to a crimp terminal
- FIG. 2 is a plan view of the crimp terminal.
- the crimp terminal 10 manufactured by the manufacturing method according to the present embodiment is a female crimp terminal, and includes a box portion 20 and a crimp portion 30.
- the crimping portion 30 of the crimp terminal 10 allows crimping connection to the aluminum core wire 51 that is a conductor portion of the covered electric wire 50, and the covered electric wire 50 is crimped to the crimping portion 30.
- an example of a female terminal into which an insertion tab such as a male terminal is inserted into the box portion 20 is shown.
- the shape of the details of the box portion 20 is not particularly limited. That is, as another mode, for example, a male terminal insertion tab may be provided instead of the female box portion 20.
- a covered electric wire 50 is connected to the crimping portion 30 of the crimping terminal 10.
- the covered electric wire 50 includes an aluminum core wire 51, and the aluminum core wire 51 is covered with an insulating coating 52.
- the aluminum core wire 51 is configured by bundling aluminum strands. Furthermore, an electric wire exposed portion 51 a in which the aluminum core wire 51 is exposed from the insulating coating 52 is formed in front of the covered tip 50 a of the covered electric wire 50.
- the aluminum core wire 51 is formed by twisting an aluminum alloy wire so that the cross section becomes 0.75 mm 2 .
- iron (Fe) is about 0.2 mass%
- copper (Cu) is about 0.2 mass%
- magnesium (Mg) is about 0.1 mass%
- silicon (Si ) about 0.04% by mass
- Al aluminum
- unavoidable impurities can be used.
- Fe is about 1.05 mass%, Mg is about 0.15 mass%, Si is about 0.04 mass%, the balance is Al and inevitable impurities, or Fe is about 1.0 % By mass, about 0.04% by mass of Si, the balance being Al and inevitable impurities, about 0.2% by mass of Fe, about 0.7% by mass of Mg, about 0.7% by mass of Si, and the balance Al and inevitable impurities can be used.
- These may further contain alloy elements such as Ti, Zr, Sn, and Mn.
- a core wire of 0.5 to 2.5 sq (mm 2 ) and 7 to 19 strands can be used.
- the covered electric wire 50 a copper electric wire in which a conductor made of copper or a copper alloy is covered with an insulating coating can be used instead of the aluminum electric wire.
- the core wire of the covered electric wire 50 may be a single wire.
- the core wire covering material for example, a material mainly composed of polyolefin such as PE or PP, or a material mainly composed of PVC can be used.
- the box part 20 in the crimp terminal 10 is configured in a box shape of an inverted hollow square column.
- An elastic contact piece 21 is provided inside the box portion 20.
- the elastic contact piece 21 is bent rearward in the longitudinal direction X and comes into contact with an insertion tab of a male terminal (not shown) inserted into the box portion 20.
- the box portion 20 is bent so that the side surface portions 23 provided continuously on both sides in the width direction Y orthogonal to the longitudinal direction X of the bottom surface portion 22 are overlapped, and is substantially rectangular when viewed from the front end side in the longitudinal direction X. It is configured.
- the longitudinal direction X is a direction that coincides with the longitudinal direction of the covered electric wire 50 to which the crimping portion 30 is crimped and connected as shown in FIG. 1, and the width direction Y is the longitudinal direction X.
- it is a direction intersecting on a substantially horizontal plane.
- the side of the box part 20 with respect to the crimping part 30 is defined as the front side, and conversely, the side of the crimping part 30 with respect to the box part 20 is defined as the rear side.
- compression-bonding part 30 is formed with a back side inclined part 41 having an inclination that rises toward the rear.
- compression-bonding part 30 before crimping in the crimp terminal 10 butts end part 32a which rounded the barrel component piece 32 extended to the both sides of the width direction Y of the crimping surface 31 and the crimping
- the end portions 32a are welded to form a cylindrical body.
- compression-bonding part 30 is made into substantially O type.
- the length of the barrel component piece 32 in the longitudinal direction X is the length of the insulation coating 50 in the longitudinal direction X of the wire exposed portion 51a exposed forward of the longitudinal direction X from the coating tip 52a that is the front end of the insulating coating 50 in the longitudinal direction X. It is longer than the exposed length.
- the crimping portion 30 includes a coated crimping cylindrical portion 30a for crimping the insulating coating 50 shown in FIG. 1 and an electrical wire crimping tubular portion 30b for crimping the exposed wire portion 51a of the aluminum core wire 51 disposed in front of the crimped crimping portion 30a.
- a sealing portion 30c is formed further forward of the wire crimping tubular portion 30b. The sealing portion 30c is deformed so that the front end portion overlaps the plate, and is welded in the width direction Y as shown in FIG. At this time, the sealing part may be formed so that the shape seen from the cross section perpendicular to the longitudinal direction of the crimping part 30a is substantially U-shaped.
- the crimp terminal 10 is a closed barrel type terminal including a box portion 20 of a hollow quadrangular prism body and a crimp portion 30 that is substantially O-shaped in rear view.
- Three coating locking grooves 33a which are grooves in the width direction Y, are formed in the longitudinal direction X at predetermined intervals on the inner surface of the coated crimped cylindrical portion 30a in the crimped portion 30.
- the covering locking groove 33 a is formed in an arc shape in cross section, forms a wave shape by being continuous in the longitudinal direction, and forms an annular groove continuous over the entire circumference of the crimping surface 31.
- the covering locking groove 33a is formed in such a shape so that the insulating coating 50 bites in the crimped state.
- three wire locking grooves 33b which are grooves in the width direction Y, are formed on the inner surface of the wire crimping tubular portion 30b at a predetermined interval in the longitudinal direction X.
- the wire locking groove 33b is configured to have a rectangular cross section, and forms an annular groove that continues to a midway position in the circumferential direction of the crimping surface 31.
- the electric wire locking groove 33b has such a shape, the aluminum core wire 51 bites into the electric wire locking groove 33b in a crimped state.
- the electrical connection between the crimping part 30 and the aluminum core wire 51 is improved.
- the crimp terminal 10 is not limited to the mode shown in FIGS. 1 and 2, and can be configured in the mode shown in FIG. 3. That is, the inclined portion B is provided between the coated crimped tubular portion 30a and the wire crimped tubular portion 30b of the crimped portion 30 shown in FIG.
- the inner diameter of the wire crimping cylindrical portion 30b is configured to be smaller than the inner diameter of the coated crimping cylindrical portion 30a. That is, the crimping portion 30 that matches the outer diameter of the covered electric wire 50 is configured by increasing the diameter of the portion of the covered electric wire 50 (not shown) that covers the insulating coating 52 and reducing the diameter of the portion that covers the aluminum core wire 51.
- the unwinding roll 110 is a mechanism for unwinding and supplying the copper strip C, which is a workpiece to be processed, wound in a roll shape at a predetermined speed.
- the unwinding roll 110 continuously feeds the copper strip C from the roll at a speed mainly considering the press processing timing in the press machine 120.
- the copper strip C is intermittently conveyed in accordance with the timing of the press work. Therefore, as shown in FIG. 4, between the unwinding roll 110 and the press machine 120, the copper strip C is given a certain slack to absorb the difference in the conveyance timing between the intermittent conveyance and the continuous conveyance. ing.
- the press machine 120 is a device that forms a chain terminal T by performing press molding such as punching or bending while intermittently transporting the copper strip C supplied from the unwinding roll 110 by a feed mechanism (not shown). .
- press molding such as punching or bending
- the laser welding machine 130 is a device that joins the abutting portion Td formed in the bent portion of the chain terminal T by laser welding to make the electric wire connecting portion a sealed structure.
- Fiber laser welding is used for laser welding of the laser welding machine 130. Since the fiber laser has excellent beam quality and high condensing property, it is possible to realize laser welding having a higher energy density in the processing region than a conventional laser. For this reason, it is possible to process the material at high speed, and there is little thermal influence, and deep penetration welding with a high aspect ratio is possible. Therefore, the two end portions 32a are suppressed while suppressing the strength reduction and deformation of the crimping portion 30. Can be appropriately sealed.
- the fiber laser may be irradiated by continuous oscillation, pulse oscillation, QCW oscillation, or pulse-controlled continuous oscillation.
- the fiber laser may be a single mode or multimode fiber laser.
- the laser workability inspection machine 140 is an apparatus for inspecting the workability of the laser-welded chain terminal T2. Specifically, with respect to the welding condition at the butted portion Td laser-welded by the laser welding machine 130, it is determined by an imaging means such as a CCD camera whether the positional deviation amount or bead width in the axial direction of the welding position is within an allowable range. To do.
- the chain terminal T In the conveyance path between the press machine 20 and the laser welding machine 130, the chain terminal T is conveyed with a slack. Similarly, in the conveyance path between the laser welding machine 130 and the laser workability inspection machine 140, the chain terminal T is conveyed with slack. This is because the processing timing of the press machine 20 and the laser welding machine 130, the laser welding machine 130 and the laser workability inspection machine 140 is shifted, and this is absorbed by the slack of the chain terminal T between the processes. is there.
- the winding roll 150 is a mechanism for winding the chain terminal T2 at the same speed as the unwinding roll 10.
- the chain terminal T ⁇ b> 2 is intermittently synchronized with the timing of the laser processing or inspection process in the laser welding machine 130 or the laser workability inspection machine 140 in the previous process.
- the chain terminal T ⁇ b> 2 has a certain slack between the winding roll 150 and the laser workability inspection machine 140, and the conveyance timing between the intermittent conveyance and the continuous conveyance, as shown in FIG. 4. To absorb the differences.
- the laser welder 130 and the laser workability inspection machine 140 are separately configured as separate apparatuses.
- the laser workability inspection is included in the laser welder 130. It is also possible to incorporate the function of the machine 140. That is, in the laser welding machine 130, it is realizable by providing an image inspection camera on the downstream side where the laser processing unit is provided and on the conveyance path of the chain terminal T2.
- the outline of the manufacturing method of the crimp terminal according to the present embodiment will be described.
- the copper strip C shown in FIG. 5A is pressed by the press machine 2 shown in FIG.
- a crimping terminal 10 shown in FIGS. 1 and 2 is manufactured through a welding process in which laser welding is performed.
- the copper strip C is a metal pre-processing plate material made of a copper alloy strip such as brass having a copper (Cu) content of 70% or more and having a surface plated with tin (Sn plating). More specifically, a copper alloy FAS-680 (thickness: 0.25 mm) manufactured by Furukawa Electric is used as the optimum base material.
- the alloy composition of FAS-680 is that nickel (Ni) is 2.0 to 2.8% by mass, silicon (Si) is 0.45 to 0.6% by mass, and zinc (Zn) is 0.4 to 0.55. It contains 0.1% to 0.25% by mass of tin (Sn) and 0.05 to 0.2% by mass of magnesium (Mg), with the balance being copper (Cu) and inevitable impurities.
- a metal plate before processing it can replace with the copper strip C, and can also use the plate material and strip material using metals other than copper, such as a steel plate and an aluminum plate.
- a base material made of a metal material (aluminum, steel, or an alloy containing these as a main component).
- tin plating, silver plating, or the like may be applied to part or all of the crimp terminal.
- the chain terminal T1 before final press processing includes a plurality of pre-bending crimp terminals Ta to be the crimp terminals 10 after processing, and an upper carrier portion C1 and a lower carrier portion that are connected to the plurality of pre-bending crimp terminals Ta and supported during conveyance. It is constituted by C2.
- the upper carrier part C1 is a band-shaped holding member disposed on the upper part of the crimp terminal Ta before bending.
- the lower carrier part C2 is disposed below the pre-bending crimp terminal Ta serving as a plate material.
- the crimping terminal Ta before bending in the chain terminal T1 before final pressing is subjected to bending processing, and as shown in FIG. 5C, the barrel portion Tv and the connector portion Tc serving as barrel members are formed.
- a pre-welding crimp terminal Tb is formed.
- the barrel portion Tv is a cylinder formed by juxtaposing the sides of the barrel portion Tv, specifically, a cylinder having side sides attached to each other. Then, the end portion on the connector portion Tc side which is one end side in the longitudinal direction in the barrel portion Tv is pressed and crushed, and the opening portion on the connector portion Tc side in the barrel portion Tv is closed to form a closed portion.
- the inclined portion Ts is formed on the connector portion Tc side by crushing the end portion of the barrel portion Tv, and the cylindrical portion remaining without being crushed is defined as a cylindrical portion Tp. Further, the tip portion of the inclined portion Ts becomes the sealing portion Tf.
- a crimp terminal having water-stopping property is manufactured by welding the butted portion Td and the sealing portion Tf of the cylindrical body portion Tp with a laser welding machine (not shown).
- the crimp terminal obtained by welding the butted portion of the cylindrical portion Tp and the sealing portion Tf inserts the covered electric wire 50 from the direction opposite to the box portion 20 of the electric wire crimping cylindrical portion 30b, and the electric wire crimping cylindrical portion 30b.
- the wire crimping cylindrical portion 30b and the aluminum core wire 51 are crimped using a crimping tool (not shown).
- the aluminum core wire 51 is crushed into the wire locking groove 33b on the inner surface of the wire crimping tubular portion 30b, and the crimped portion is crimped.
- crimping a new surface is created at the interface of the metal body when it is crushed with mechanical strength, and the new surface comes into contact with each other, thereby realizing a reliable electrical connection.
- the electrical connection between the inner surface of the wire crimping tubular portion 30b and the aluminum core wire 51 is not limited to the method performed by providing the wire locking groove 33b.
- the electric wire crimping cylindrical portion 30b is caulked with a pushing blade die composed of a receiving die and a pressing die, as shown in FIG. It is also possible to electrically connect the inner surface of the electric wire crimping cylindrical part 30b and the aluminum core wire 51 by pushing into the surface of the electric wire crimping cylindrical part 30b.
- the butted portion and the sealing portion Tf of the laser-welded cylindrical body portion Tp need to be laser-welded so as to satisfy the crimping force when crimping, the mechanical strength after crimping, and the electrical connectivity. . Therefore, as a result of studying various parameters related to welding characteristics such as laser beam intensity and sweep speed, after laser welding, crimping is performed by optimally controlling the width of the weld bead that can be formed at the butt portion. It was confirmed that the crimping force at the time, the mechanical strength after crimping, and the electrical connectivity were satisfactory. In other words, by measuring only the weld bead width after laser welding, it is possible to guarantee a crimp terminal that maintains reliability even after crimping. Specifically, the laser beam power density and the laser beam sweep speed are set so that the width of the weld bead is 80 ⁇ m to 390 ⁇ m, preferably 180 ⁇ m to 270 ⁇ m.
- the laser beam is irradiated from one end to the other end of the butted portion of the cylindrical portion Tp of the crimping portion 30 and the sealing portion Tf.
- the weld bead width D shown in FIG. 7 is 80 ⁇ m to 390 ⁇ m, preferably 172 ⁇ m to 273 ⁇ m.
- the weld bead width D is less than 80 ⁇ m, there is a possibility of non-penetrating welding. If there is a non-penetrating weld, it will cause the weld to break when crimped to the wire end. Also, if the width D of the weld bead is larger than 390 ⁇ m, various effects such as an increase in spatter due to excessive heat input, a decrease in water stoppage performance due to melting of the weld thinning due to an increase in spatter, a decrease in wire insertion property, etc. can be considered. .
- compression-bonding part 30 are overlap
- through welding is performed by sweeping the overlapping portion 95 while irradiating the overlapping portion 95 with laser light so that the width of the weld bead B formed on the outer surface side of the crimping portion 30 is 80 ⁇ m to 390 ⁇ m, preferably 172 ⁇ m to 273 ⁇ m. Is done.
- the total thickness of the overlapped portions needs to be 0.8 mm or less. Therefore, when using a plate material having a plate thickness of 0.5 mm and overlapping the end portions, it is necessary to process the end portions so that the plate thickness is reduced in advance. The processing can be performed with a taper shape or a step.
- this invention is not limited to the above embodiment.
- the crimp portion of the crimp terminal is crimped and connected to the wire conductor made of aluminum or aluminum alloy.
- the wire made of metal other than aluminum or aluminum alloy for example, copper or copper alloy Even if it is crimp-connected to the conductor, substantially the same operations and effects as those of the above embodiment can be obtained. Since the crimping portion having the above-described configuration can prevent water from entering in the crimped state, for example, a covered electric wire configured with a core wire such as copper or a copper alloy that has been required to have a seal or the like for water-stopping between lines so far May be connected.
- Example 1 Example using copper alloy
- the conditions of the present embodiment are as follows.
- the plate material the above-mentioned copper alloy FAS-680 (thickness 0.25 mm) manufactured by Furukawa Electric was used.
- the wavelength of the laser beam is 1084 nm.
- the output of the laser beam is 400W.
- the spot diameter of the laser light is about 20 ⁇ m.
- the power density of the laser light is 96 MW / cm 2 .
- the laser beam sweep speed was appropriately adjusted from 20 mm / sec to 400 mm / sec. In Table 1, only typical ones are shown.
- the bead width is a weld bead width ( ⁇ m) when the abutting surface of the plate material at the abutting portion of the cylindrical body portion Tp and the laser irradiation axis coincide with each other.
- the column next to the right of the “bead width” column shows “weldability”.
- weldingability the evaluation results are indicated by “ ⁇ ”, “ ⁇ ”, “ ⁇ ′”, “ ⁇ ”, “ ⁇ ”.
- ⁇ indicates that welding was possible even when the laser irradiation axis deviated at least ⁇ 60 ⁇ m from the butted surface, and the weld cross section was good.
- ⁇ indicates that welding was possible even when the laser irradiation axis deviated by at least ⁇ 40 ⁇ m from the butted surface, and the weld cross section was good.
- “ ⁇ ” indicates that welding can be performed even if the laser irradiation axis deviates by at least ⁇ 60 ⁇ m with respect to the butted surface, but the thermal effect on the base material around the welded portion is large. “ ⁇ ” indicates that welding can be performed even if the laser irradiation axis deviates at least ⁇ 20 ⁇ m from the butted surface. “X” indicates that through-welding was not possible due to insufficient penetration, or the weld was melted down due to excessive melting.
- evaluation results are indicated by “ ⁇ ”, “ ⁇ ”, and “ ⁇ ”.
- This evaluation result is a result of evaluating whether or not the crimp terminal can withstand crimping when the crimped tubular portion 30b and the aluminum core wire 51 are crimped after welding.
- the appearance inspection after crimping was indicated by “ ⁇ ” when it was able to withstand crimping, “x” when it was not able to withstand crimping, and “ ⁇ ” when neither could be evaluated.
- the weldability was evaluated as “ ⁇ ”, “O”, “O ′”, “ ⁇ ” when the weld bead width was 80 ⁇ m to 390 ⁇ m.
- the weld bead width was 172 ⁇ m to 273 ⁇ m, there was no problem in the weld cross section, and the evaluation was “ ⁇ ”.
- welding is possible when the weld bead width is 286 ⁇ m to 390 ⁇ m (“ ⁇ ” evaluation) and 400 ⁇ m (“ ⁇ ” evaluation), but spatter increases due to excessive heat input, the weld is melted down, and the internal voids in the weld The occurrence of was confirmed.
- the weld bead width is 80 ⁇ m to 89 ⁇ m (“ ⁇ ” evaluation)
- welding is possible.
- the weld cross section is observed, a non-penetrated weld area that cannot be welded to the back of the plate is seen, and the focus is set. The accuracy was found to be close to the limit.
- weld bead width is 76 ⁇ m (“ ⁇ ” evaluation) or less, welding is impossible due to non-penetrating welding, and when the weld bead width is 400 ⁇ m (“ ⁇ ” evaluation) or more, welding is not possible because welding is melted down.
- the weld bead width is 101 ⁇ m to 365 ⁇ m, even if the crimping of the wire crimping cylindrical portion 30b and the aluminum core wire 51 is performed, Since there was no problem, the evaluation of crimping is “ ⁇ ”. Further, when the weld bead width is 80 ⁇ m to 97 ⁇ m, the welding of the part where the non-penetrating weld is seen is possible.
- the weld bead width was 390 ⁇ m, a part of the weld bead, specifically, the weld bead on the electric wire insertion side was melted down, so that the evaluation of crimping was “ ⁇ ”.
- the weld bead width was 76 ⁇ m or less and 400 ⁇ m or more, non-penetrating welding or burn-out of the welded portion occurred, and therefore the evaluation of the crimping was also set to “x”.
- the laser beam output is 400 W
- the laser beam spot diameter is about 20 ⁇ m
- the laser sweep speed is 130 mm / sec
- welding is performed.
- the bead width was 200 ⁇ m
- the evaluations of weldability and crimpability were “ ⁇ ” and “ ⁇ ”, respectively.
- the power density of the laser beam and the sweep rate of the laser beam are set so that the width of the weld bead is 80 ⁇ m to 390 ⁇ m, preferably 101 ⁇ m to 365 ⁇ m, and more preferably 172 ⁇ m to 273 ⁇ m.
- the weld bead width in such a range, it is possible to guarantee a crimp terminal that maintains reliability even after crimping by measuring only the weld bead width after laser welding.
- Example 2 Example using brass
- the conditions of the present embodiment are as follows.
- C2600 (thickness 0.25 mm) which is seven three brass was used for the plate material.
- a fiber laser was used as the laser light source.
- the wavelength of the laser beam is 1084 nm.
- the spot diameter of the laser beam is about 60 ⁇ m.
- the power density of the laser light is 12 MW / cm 2 .
- the laser beam sweep rates are 100 mm / sec, 200 mm / sec, 250 mm / sec, 300 mm / sec, and 400 mm / sec. The results are shown in Table 2 below.
- the laser beam power density and the laser beam sweep speed so that the width of the weld bead is 80 ⁇ m to 390 ⁇ m, preferably 180 ⁇ m to 270 ⁇ m.
- Example 2 when C2600, which is seven-three brass shown in Example 2, is used for the plate material, the plate thickness in Example 2 was 0.25 mm. Experiments were performed at 3 mm, 0.385 mm, 0.64 mm, and 0.8 mm. A fiber laser was used as the laser light source.
- the laser beam power density and the laser are adjusted so that the width of the weld bead is 80 ⁇ m to 390 ⁇ m, preferably 180 ⁇ m to 270 ⁇ m.
- the light sweep rate it is possible to guarantee a crimp terminal that maintains reliability even after crimping.
- Fe-containing copper alloys for example, KLF-5 and KLF194 manufactured by Kobe Steel, Ltd.
- Cr-containing copper alloys for example, EFTEC-8 and EFTEC-64T manufactured by Furukawa Electric Co., Ltd.
- Corson series Copper alloy for example, FAS-680 manufactured by Furukawa Electric Co., Ltd., MAX251 manufactured by Mitsubishi Shindoh Co., Ltd.
- a copper alloy containing a large amount of Ni or Sn for example, MX96 manufactured by Mitsubishi Electric Metex Co., Ltd.
- copper containing Mg An alloy for example, MSP1 manufactured by Mitsubishi Shindoh Co., Ltd.
- the results were as shown in Table 4 below.
- the laser spot diameter is about 20 ⁇ m
- the plate thickness is 0.25 mm.
- the measurement results in the case of lap welding are shown in Table 5 below.
- the spot diameter of the fiber laser in this measurement is about 20 ⁇ m
- the thickness of the welded portion is a thickness obtained by stacking two plate materials having a plate thickness of 0.25 mm, that is, 0.5 mm.
- the width of the weld bead As described above, by setting the width of the weld bead to 80 ⁇ m to 390 ⁇ m for a copper alloy having a copper content of 70% or more, it is possible to provide a terminal with good welding quality and resistance to crimping. It is.
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Abstract
Description
図1に示すように、本実施形態に係る製造方法で製造された圧着端子10は、雌型圧着端子であり、ボックス部20および圧着部30を備えている。圧着端子10の圧着部30は、被覆電線50の導体部分であるアルミニウム芯線51に対する圧着接続を許容しており、圧着部30には、被覆電線50が圧着される。
続いて、本実施形態に係る圧着端子の製造方法について、図4を用いて当該製造方法を実施する装置を説明するとともに、図5を用いて圧着端子の製造手順を説明する。
以下、端子製造装置100の各構成について説明する。
本実施形態に係る圧着端子の製造方法の概要を説明すると、図5(a)に示す銅条Cについて、図4に示したプレス機2によってプレス加工を施すプレス工程、およびレーザ溶接機3によってレーザ溶接を施す溶接工程を経て、図1および図2に示す圧着端子10を製造する。銅条Cは、銅(Cu)の含有量が70%以上であって、表面が錫めっき(Snめっき)された黄銅等の銅合金条からなる金属製の加工前板材である。より具体的には、最適な基材として、古河電気工業製の銅合金FAS-680(厚さ0.25mm、)を用いる。FAS-680の合金組成は、ニッケル(Ni)を2.0~2.8質量%、シリコン(Si)を0.45~0.6質量%、亜鉛(Zn)を0.4~0.55質量%、スズ(Sn)を0.1~0.25質量%、およびマグネシウム(Mg)を0.05~0.2質量%含有し、残部が銅(Cu)および不可避不純物である。
上述の通り、レーザ溶接後の溶接ビード幅のみを測定することで、圧着後でも信頼性を維持した圧着端子を保証することが可能になることを示すため、下記の表1に示すように、レーザ溶接におけるレーザ光の掃引速度を20mm/sec~400mm/secまで変化させることにより、溶接性、溶接後の圧着性を調べた。レーザ光源にはファイバレーザを用いた。
「◎」は、突き合わせ面に対してレーザの照射軸が少なくとも±60μmずれても溶接でき、且つその溶接断面が良好であったことを示している。
「○」は、突き合わせ面に対してレーザの照射軸が少なくとも±40μmずれても溶接でき、且つその溶接断面が良好であったことを示している。
「○’」は、突き合わせ面に対してレーザの照射軸が少なくとも±60μmずれても溶接できるが、溶接部の周辺における母材への熱影響が大きいことを示している。
「△」は、突き合わせ面に対してレーザの照射軸が少なくとも±20μmずれても溶接できことを示している。
「×」は、溶け込み不足のため貫通溶接できないか又は過剰溶融のため溶接部が溶け落ちたことを示している。
続いて、レーザ溶接後の溶接ビード幅のみを測定することで、圧着後でも信頼性を維持した圧着端子を保証することが可能になることを示すため、実施例2として圧着端子を構成する板材に、黄銅を用いた実施例を示す。
他の実施例として、圧着端子の板材の板厚を変更した場合においても、溶接ビードの幅寸法を80μm~390μm、望ましくは180μm~270μmになるようにレーザ光のパワー密度とレーザ光の掃引速度を設定することで、圧着後でも信頼性を維持した圧着端子を保証することが可能となる。
20…ボックス部
21…弾性接触片
22…底面部
23…側面部
30…圧着部
30a…被覆圧着筒状部
30b…電線圧着筒状部
30c…封止部
30d…傾斜部
31…圧着面
32…バレル構成片
32a…端部
33a…被覆用係止溝
33b…電線用係止溝
40…連結部
41…裏面側傾斜部
50…被覆電線
50a…被覆先端
51…アルミニウム芯線
51a…電線露出部
52…絶縁被覆
95…重ね合わせ部
100…端子製造装置
110…巻出しロール
120…プレス機
130…レーザ溶接機
140…レーザ加工性検査機
C…銅条
C1…上キャリア部
C2…下キャリア部
T1…最終プレス加工前連鎖端子
T2…連鎖端子
Ta…曲げ加工前圧着端子
Tb…溶接前圧着端子
Tc…コネクタ部
Td…突き合わせ界面
Tv…バレル部
Ts…傾斜部
Tp…筒体部
Tf…封止部
M…製造装置
H…送り穴
X…長手方向
Y…幅方向
Z…上下方向
B、D…溶接ビード幅
Claims (13)
- 被覆電線の導体部分に対する圧着接続を許容する圧着部を備える圧着端子の製造方法であって、
金属製の板材における側辺同士を互いに合わせて筒体を形成し、
合わせた前記側辺の周辺にレーザ照射手段からレーザ光を照射させることで、合わせた前記側辺を溶接し、
溶接後に前記側辺部分に形成された溶接ビードの幅寸法を80μm~390μmになるようにレーザ光のパワー密度とレーザ光の掃引速度を設定することを特徴とする圧着端子の製造方法。 - 前記レーザ照射手段のレーザ光源はファイバレーザであることを特徴とする請求項1記載の圧着端子の製造方法。
- 溶接後に前記側辺部分に形成された溶接ビードの幅寸法を172μm~273μmになるように、レーザ光のパワー密度とレーザ光の掃引速度を設定することを特徴とする請求項1又は2記載の圧着端子の製造方法。
- レーザ光が照射される前記筒体の厚さを0.8mm以下に調製することを特徴とする請求項1又は2記載の圧着端子の製造方法。
- 被覆電線の導体部分に対する圧着接続を許容する圧着部を備える圧着端子であって、
金属製の板材における側辺同士を互いに合わされた合わせ部と、
レーザ照射手段から照射されるレーザ光を当てることで、前記合わせ部に形成された溶接ビード部と、を有し、
前記溶接ビード部の幅寸法が80μm~390μmであることを特徴とする圧着端子。 - 前記レーザ照射手段のレーザ光源はファイバレーザであることを特徴とする請求項5記載の圧着端子。
- 前記溶接ビード部の幅寸法が101μm~365μmであることを特徴とする請求項5又は6記載の圧着端子。
- 前記溶接ビード部の幅寸法が172μm~273μmであることを特徴とする請求項7記載の圧着端子。
- 前記合わせ部の厚さが0.8mm以下であることを特徴とする請求項6~8のいずれか1項に記載の圧着端子。
- 前記合わせ部は、前記側辺を突き合わせることで形成されていることを特徴とする請求項6~9のいずれか1項に記載の圧着端子。
- 前記合わせ部は、前記側辺を重ね合わせることで形成されていることを特徴とする請求項6~9のいずれか1項に記載の圧着端子。
- 1又は複数の被覆電線を有するワイヤハーネスであって、
前記被覆電線の端部に、請求項6~11のいずれか1項記載の圧着端子が設けられていることを特徴とするワイヤハーネス。 - 前記被覆電線の導体部分がアルミニウム又はアルミニウム合金からなることを特徴とする請求項12記載のワイヤハーネス。
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KR1020147028808A KR101493205B1 (ko) | 2013-02-22 | 2014-02-24 | 압착 단자의 제조 방법, 압착 단자 및 와이어 하네스 |
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EP14754350.8A EP2961010B8 (en) | 2013-02-22 | 2014-02-24 | Method for manufacturing crimp terminal, crimp terminal, and wire harness |
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Also Published As
Publication number | Publication date |
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CN104272535B (zh) | 2019-03-19 |
EP2961010A4 (en) | 2016-12-07 |
JP2015133310A (ja) | 2015-07-23 |
JP6301768B2 (ja) | 2018-03-28 |
US9564691B2 (en) | 2017-02-07 |
CN104272535A (zh) | 2015-01-07 |
EP2961010B8 (en) | 2018-05-23 |
JPWO2014129640A1 (ja) | 2017-02-02 |
JP5598889B1 (ja) | 2014-10-01 |
US20150364837A1 (en) | 2015-12-17 |
KR20140130561A (ko) | 2014-11-10 |
EP2961010B1 (en) | 2018-04-11 |
EP2961010A1 (en) | 2015-12-30 |
KR101493205B1 (ko) | 2015-02-12 |
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